I had not noticed this thread the first time around, but now I think I'd better have a look at my wife's akas. My boat is newer and I may as well check it too since it has the akas off my first hull. I don't remember noticing a lot of corrosion when they were moved from old to new.

The stainless bolts on the front Xbar had a good amount of corrosion but weren't frozen ... the rears I couldn't budge. Inserts looked cruddy but serviceable. I'll shoot it all with penetrating oil and run a chase through the inserts

Mine were slotted like yours. This allows for a little calibration of the bars, so things may slip around a make noises if the bolts are loose. I would check for other sources like the v brace though. If the Aka joints were frozen they probably were not the culprit.

As long as your soc bolthead or washers can not pull through the slotted holes, you are fine. Slightly larger washers can still be added.

everything else was checked/tightened so I was excited to see this new possible cause and even more sure of the source when I saw what I thought were worn/elongated holes ...

Bolts were tight up front ... didn't try tighetening any more before loosening. Tight enough so as to prevent movement ? IDK. I'd wager this is the first tiime they've been removed since initial construction.

Welp - Im back up and running. First, Second, and Third sail of the season was on Fri/Sat/Sun and all seems good.

I did a good solid clean-up and repaint with some Rustoleum I had laying around and re-rigged using new Stainless bolts and slightly larger washers and a dab of anti-sieze

. I did take a Dremel to the inserts and ever so carefully flushed (or slightly recessed) them to the deck - I've become somewhat of a Dremel Maestro building R/C model airplanes for over 25 years. Not something I'd recommend for someone having little experience with one simply because the danger of ripping into the deck if/when the bit grabs has a high percentage. My one bit of advice when working with a dremel - very little pressure, lowest speed to do the job, and let time and the tool do the work.

So - I didn't experience any of the previous "popping" noises during or after a tack (or at all for that matter ...) but the winds weren't what I'd call exciting ... 8-12mph with an occasional blow of 15 or so but not sustained. I purposely did not attempt any other adjustments (turnbuckles etc...) because then I wouldn't be sure what the solution was ... and I had previously adjusted things below deck without eliminating the POP.

I guess the real test will be when the winds are a bit severe.

All in all Im glad I did remove the Xbars and inspect - If yours is an older model I strongly suggest you take the time to do so as well. IF I decide I am going to keep this particular boat then I may order at least the front Xbar to have as a spare when things worsen a bit